Tufted dot fabric



Aug. 1, 1950 INVENTOR. M 4, AN: 2:

Y QMQP Arm/mew Patented Aug. 1, 1950 TUFTED DOT FABRIC Leonard A.Stanley, Slatersville, B. 1., amino:- to t The Kendall Company, Boston,Mass.

ration of Massachusetts Application March 13, 1947, Serial No. 734,565

, 5'Clalms. (01. 28-80) This invention relates to tufted dot fabricshaving novel properties of washfastness and to methods of making thesame.

Fabrics of the type concerned have a woven fabric base, frequently ofrelatively open mesh weave such as a marquisette, the surface of whichis dotted with spaced fiuffy tufts of projecting fibers, formed ofslack-twisted fiber rovings anchored at intervals to the base fabric,usually by interweaving, and sheared to form the dot pattern. Suchfabrics are ordinarily used for making curtains, often called fiuify dotcurtains or puffy dot curtains," for which purpose light-weight plain orleno woven base fabrics are usually employed, such as marquisettes,scrims, lawns, voiles, organdies and the like.

In the manufacture ofsuch fabrics heretofore,

it has been the practice to apply starch or other stiflening, sizing orfinishing agent to the base or ground fabric only, leaving the dot tuftsuntreated and in a soft, fiuffy, upstanding condition. This upstandingcondition is produced by subjecting the dots, prior to finishing of theground fabric, to a fluffing operation in which the dry. unsized fibersof the tufts are either mechanically brushed or blown with compressedair. Care is exercised to avoid the application of such stiffeningagents to the tufted dots since, if that were done, it was found thatthe fibers of the dots were so stiffened and matted and stuck togetherand to the ground fabric by the hardened size that it was not possibleto fiuif them into the required form of upstanding soft downy tufts.

These tufted dot fabrics, as heretofore produced, have been subject to aserious defect in that washing destroys the fiuffy character of thedots. After washing, the fibers of the dot tufts no longer stand upindividually from the fabric in regular shaped, downy tufts, but arematted and. stuck together into hard irregular shaped pills. Thispilling of the dot fibers is accentuated by starching, and if the fabricis ironed the pilled dots are permanently flattened 'onto the basefabric, in the form of stiff, paper-like masses of irregular outline.These physical changes in the dot tufts resulting from washing produce astartling and unpleasant change in the appearance of the fabric andlargely destroy the ornamental value of the dots.

The object of this invention is to produce a novel tufted dot fabricwherein the dots remain in the form of soft, fluffy, uniform, upstandingtufts after washing and to provide a method for making such a fabric.

2 I have discovered that certain thermosetting resins, when properlyincorporated with the dot tuft fibers and polymerized, have thesurprising property of orienting the fibers wash-fast in the positionthey assume at the time of curing of the resins without, however,stiffening the fibers. Furthermore, I have discovered a method forapplying these resins to the dot tufts during the manufacturing andfinishing of the fabric whereby the natural tendency of these resins, asof other sizing agents, to mat and stick the tuft fibers to one anotherand to the base fabric is overcome and the condensation of the resinfixes the fibers wash-fast in the form of upstanding, soft, fiuffytufts, substantially indistinguishable in appearance and feel from theunsized, nonwash-fast flufly dots of such fabrics as heretoforeproduced. I

The dot tufts of fabrics produced'according to this invention retaintheir original soft, fiufiy, upstanding condition despite repeatedlaunderings, whether by normal hand, home machine or commercial machinelaundering methods and whether the washed fabrics are dried smooth bypin framing or are ironed. The tufts also have increased resistance tostiffening and pilling by starch but the use of starch in laundering ispreferably avoided and may be rendered unnecessary by incorporating awash resistant stiffening agent in the ground fabric during manufacture.

The thermosetting resins which I have found capable of imparting thisremarkable washability quality to the tufted dots of such fabrics arethe water-soluble monomers or water-soluble low polymers of the methylolureas, the watersoluble methylol melamines and the water-solublelow-molecular-weight-alkyl ethers of said methylol ureas and saidmethylol melamines, when condensed to a water insoluble condition inassociation with the dot tuft fibers. Any of these resins, or mixturesthereof, applied to the dot tuft fibers to the extent of about 2% resinsolids based on fiber weight and polymerized or condensed to awater-insoluble state produces an appreciable improvement inwashfastness of the dot tufts, the extent of washability increasing withlarger amounts of the resin. Preferably, the amount of the resin appliedto the tufts is between 5% and 15%, as Ihave found that an amount of theresin within this range, when properly. applied as hereinafterdescribed, is sufllcient to impart full washability to the dot tufts.The exact amount of resin which it is most desirable to employ withinthese limits depends largely upon the nature of the fabric and or spikedeffect on the tufts due to matting to-' gether and stiffening of thefiber ends, this being particularly the case with the melamine resins.This tendency, however, can be mitigated by including withthe resin acationic softener, for example a higher aliphatic quaternary -ammoniumhalide.

The thermosetting'resin may be applied in the form of a dispersion in aliquid carrier, preferably aqueous, which is used to impregnate the.

dot tufts only, or both the tufts and the ground fabric. The dispersionshould include an acid catalyst which accelerates polymerization of the'resin. This catalyst may be either a naturally acidic substance such aszinc chloride solution, or one, such as iii-ammonium hydrogen phosphate,that by thermodissociation produces an acidic material.

The fiuid resin composition with which the tufts are impregnated has anatural tendency to stick the'flbers of the tufts together and to thebase fabric, as is the case with starch and other sizes. I havediscovered, however, that this tendency can be overcome by subjectingthe dot tufts, after impregnation with the resin but beforepolymerization of the resin, to a fluffing operation such as that usedheretofore in fiufling the dots prior to sizing of the ground fabric, inwhich flufiing is produced by blasting the dots with a jet of compressedair or by mechanical brushing of the tuft fibers, the compressed airblast treatment being preferred as more effective and less likely tocause removal of the resin from the tufts. Preferably, this fluftlngoperation is preceded by a partial drying of the fabric which isinsuflicien't to substantially polymerize the resin.

After impregnation and fiufllng of the dot tufts, the fabric is exposedto elevated tempera- I ture for a period sufficient to dry the fabricand cause substantially complete polymerization of the resin, forming awater-insoluble condensation product. The temperature may for example befrom 300 to 400 F. and the time of exposure from /2 to 3 minutes,depending on the temperature, the type and weight of fabric, the typeand amount of catalyst present and the amount of moisture in the fabric.

Where, as is usual with light-weight curtain fabrics, it is desirable toapply a stiffening size to the ground fabric, the ground fabric isimpregnated with the size without impregnating the tufts by the usualback-starching operation in which the back, untufted surface of thefabric only is contacted with the stiffening composition, so that thecomposition is absorbed into the groundfabric but not to any substantialextent into the tufts. Such back-starching operation may precede orfollow the impregnation of the dot tufts, or the tufts and groundfabric, with the washability imparting thermosetting resin. While theground size may or may not be washresistant, I preferably use awash-resistant stiifening agent, such as certain styrene, vinyl oracrylate resins, to obviate the use of starch in laundering.

The initial steps'in the finishing of the fabric, after clipping of thewoven-in rovings to form the tufted dots, may be conventional and willordinarily include bleaching and drying and may also include mercerizingor dyeing or both.

Although the thermosetting, washability-imparting resin may be appliedthe dot tufts i only, I prefer, where the ground fabric is oflightweight, to app y the resin both to the tufts and to the groundfabric, since I have found that the formed of any of the usual naturalor regenerresins which are operative to effect washability of the dottufts also have a desirable dimensional stabilizing efiect on suchground fabrics when condensed therein which reduces shrinkage thereof inlaundering. In addition, these thermosetting resin condensation productshave a tendency to increase the wash-fastness of stiffening finishesapplied to the ground fabric. 'lhese effects on the ground fabric aresubstantial with the preferred range of proportions of resin to fiberweight for imparting washability to the tufts.

The entire fabric may be impregnated with the fluid resin composition inany suitable manner as by padding, spraying, etc., so controlled thatthe fabric absorbs the amount of fiuid required to yield the desiredamount of resin solids on drying. I preferably employ for this purpose aconventional type of padder. Impregnation of the dot tufts only may beaccomplished, for example, by contacting the dot tufts only with a filmof the resin composition on the surface of a rotating applicator roller.

After impregnation of the entire fabric or of the dots only with thethermosetting resin composition it is preferred to partially dry thefabric by passage over hot cans or through a heated tenter frame, thetime-temperature relation being adjusted so that a substantial part ofthe liquid of the impregnating resin composition is removed withoutcausing substantial resin polymerization.

I have found that thorough fiufling of the dots after their impregnationwith the thermosetting resin and prior to condensation of the resin iscritical to'the production of afiuffy dot product since the impregnationmats and sticks the fibers together and to the ground fabric, and if theresin is polymerized in that condition of the fibers they are therebyoriented wash-fast in the matted and flattened state and not in thedesired fluffy condition.

The aforesaid preferred partial drying of the resin-impregnated dotsprior to fiufling allows optimum orientation of the moist tuft fibers inthe desired soft, fiuify upstanding position. The appearance of thefinished product before and after washing is dependent upon theprocessing at this stage, as the degree of fiufliness thereafterobtained is largely governed by this tuftfiber separation and flufiingprior to the curing of the resin incorporated therewith.

After fiufling of the resin-impregnated dots, whether or not preceded bypartial drying, the fabric is subjected to heating sufficient tocompletely dry the fabric and polymerize the resin, for example bypassing over a tenter frame or through a curing oven heated between 300and 400 F. i

A fabric conforming to the invention is illustrated by the accompanyingdrawing in which the ground is indicated by the numeral ill, theresin-treated tufts by the numeral i2. Asv previously indicated theground itself may or may not be impregnated with the fluid resincomposition.

The wash-fast orientation effect of the thermosetting resins on the dottuft fibers is substantiaily independent of the character of the fibers.Hence the tufts (and ground fabric) may be ated cellulose fibersincluding cotton, linen, viscose rayon, cuprammonium rayon and the like,or mixtures of such fibers. Normally, however, the fabric and tufts areformed wholly of cotton fibers. Although the invention is not limited tolight weight tufted dot fabrics of the type commonly employed forcurtains, the benefits of the invention are greatest when appliedthereto, since the dot tufts of the lighter fabrics are more seriouslyaltered in laundering than are those of heavier fabrics when notrendered washable in accordance with this invention.

1 Tufted dot curtain fabrics finished in accordance with this inventionhave been found to retain the original soft, fluffy, symmetrical formand appearance of the dot tufts substantially unchanged after launderingby any of the following procedures. Furthermore, where the dot tuftfibers carry as much as 5% by weight of the water-insoluble condensationproduct of the thermosetting resins above set forth, they retain theirdesirable characteristics, even after as many as four of the followinglaundering procedures. These procedures are representative of normalpractice for the laundering of light fabrics which do not requirestarching.

1. A three minute wash by alternately dipping and squeezing by hand inIvory Flake soap suds at 105 F., followed by two one-minute rinses inplain water and pin framedrying or ironing. This is a normal handlaundering method for curtain fabrics.

2. Five minutes of turbulent washing in Lux soap suds at 140 F. in aMaytag washing machine, followed by wringing through a mechanicalmangle, rinsing in plain water for one minute at 100 F, re-wringing andre-rinsing for one minute, finally wringing and pin frame drying orironing. This is a typical home machine launderin; of curtain fabrics.

3. Twelve minutes of turbulent washing in Oxydol soap suds at 100 F. ina Bendix washing machine followed by three rinses and three spinnings tototal forty minutes for the complete wash, then drying, dampening andironing. This represents the most violent home machine laundering towhich curtain fabrics are likely to be subjected.

4. A ten minute soaping with 0.35% Color Suds followed by three separatefour minute rinses, all at 90 F. and in a Blanket Wheel," thencentrifugal extraction and pin frame drying. This is a representative.commercial curtain laundering procedure.

In marked contrast to the washability of my tufted dot fabrics,conventionally finished tufted dot fabrics, in which the dots are leftunfinished or unsized, when subjected to even a single launderin by anyof the foregoing procedures, exhibit a very marked loss of shape andflufliness of the tufts, due to matting and pilling or flattening of thetuft fibers, producing a most undesirable change in the appearance ofthe fabric.

While I prefer to incorporate from 5% to 15% by weight of thethermosetting resin condensation product with the dot tufts, the scopeof my invention is not limited to this preferred range of resinconcentration. For example, while washability is decreased when the dotscontain less than 5% by weight resin, even when they contain as littleas 2% resin they exhibit distinctly improved washability when comparedwith conventional unfinished dot tufts. Furthermore, I have found thatusing over 15% resin, although it does the dotted face either up or downproduces neither unsymmetrical dots nor undesirable flattening of thedot tufts, whereas ironing accentuates the adverse effects of launderingon unfinished tufts.

I claim:

1. A washable tufted dot fabric having a woven ground and a plurality ofspaced groups of fibers anchored to the ground fabric and individuallyupstanding therefrom in the form of soft, flufiy tufts forming a patternof raised dots on the fabric ground, said tuft fibers being renderedresistant to matting and flattening in laundering by carrying at leastabout 2% by weight of a waterinsoluble condensation product of athermosetting resin selected from the group consisting of theWater-soluble monomers and water-soluble low polymers of the methylolureas, the watersoluble methylol melamines and the water-solublelow-molecular-weight-alkyl ethers of said methylol ureas and saidmethylol melamines.

2. A washable tufted dot fabric having a woven ground and a plurality ofspaced groups of fibers anchored to the ground fabric and individuallyupstanding therefrom in the form of soft, fiuify tufts forming a patternof raised dots on the fabric ground, said tuft fibers being orientedsubstantially wash-fast in said upstanding fluffy condition by carryingfrom about 5% to about 15% by weight of a water-insoluble condensationproduct of a thermosetting resin selected from the group consisting ofthe water-soluble monomers and water-soluble low polymers of themethylol ureas, the water-soluble methylol melamines and thewater-soluble low molecuar weightalkyl ethers of said methylol ureas andsaid methylol melamines.

3. A washable tufted dot fabric having a lightweight, size-stiffened,woven ground fabric and a plurality of spaced groups of fibers anchoredto the ground fabric and individually upstanding therefrom in the formof soft, fluffy tufts forming a pattern of raised dots on the fabricground, said tuft fibers being essentially free of stiffening size andbeing rendered resistant to matting and flattening in laundering bycarrying at least about 2% by weight of a water-dnsoluble condensationproduct of a thermosetting resin. selected from the group consisting ofthe water-soluble monomers and water-soluble low polymers of themethylol ureas, the water-soluble methylol melamines and thewater-soluble low-molecularweight alkyl ethers of said methylol dressand said methylol melamines.

4. A washable tufted dot fabric having 9, lightweight, size-stiffened,woven ground fabric and a plurality of spaced groups of fibers anchoredto the ground fabric and individually upstanding therefrom in the formof soft, fluffy tufts forming I a pattern of raised .dots on the'fabricground,

said tuft fibers being essentially free of stiffening not materiallyimprove washability under normal 7 size and being oriented substantiallywashfast in said upstanding fluiiy condition by carrying from about 5%to about 15% by weight of a waterinsoiuble condensation product of athermosetting resin selected from the group consisting of thewater-soluble monomers and water-soluble 10w polymers of the methylolureas, the water.- soluble 'methylol melamines and the water-solubielow-moiecular-weight alkylethers or said methylol ureas and saidmethyiol melamines.

5. A washable tufted dot fabric having a lightweight, size-stiflened,woven ground fabric and a plurality of spaced groups of fibersessentially free of stiflening size anchored to the ground fabricandindividually upstanding therefrom in the form of soft iiufly tuftsforming a pattern or raised dots on the fabric ground, said tuft fibersbeing oriented substantially washfast in said upstanding fluflycondition and said ground fabric being rendered resistant to shrinkagein laundering by carrying from about 5% to about 15% by weight or awater-insoluble condensation product of a thermosetting resin selectedfrom the ureas, the water-soluble methylol melamines and thewater-soluble iow-molecular-weight alkyi ethers of said methyiol ureasand said methyiol melamines.

LEONARD A. STANLEY.

REFERENCES crrsn The following references are of record in the file ofthis patent; I UNITED STATES PATENTS Number Name Date 2,110,118Robertson Mar. 1,1938 2,128,516 Graham Aug. 30, 1938 2,155,127 GrahamApr. 18, 1939 2,160,825 Cheney June 6, 1939 FOREIGN PATENTS NumberCountry Date 497,647 Great Britain Dec. 22, 1938

